Excessive resistance in the main circuit of a circuit breaker is a critical issue in modern power systems. As a core component of the electrical grid, the circuit breaker plays a vital role in ensuring the stability and reliability of power distribution. However, inherent errors or malfunctions within the circuit breaker can lead to operational problems, making it essential to address this concern promptly. In this article, we will explore the reasons behind excessive main circuit resistance in circuit breakers and discuss effective solutions to resolve the issue.
The circuit breaker serves as both a control device and an essential element in the distribution of electric energy. Its performance directly affects the overall stability and efficiency of the power system. During operation, the main circuit resistance must remain within acceptable limits to ensure safe and efficient power transmission. Conductive materials used in the circuit are crucial for maintaining proper current flow, and any deviation from standard resistance values can create an unstable electromagnetic environment. Additionally, the complexity of the circuit breaker’s internal structure and the high demands placed on its components make it susceptible to issues such as overheating and mechanical wear, which can further increase resistance levels.
1.1 Data and Design Errors
In the design phase, the main circuit resistance of a circuit breaker should be calculated based on system capacity, rated current, and short-circuit conditions. These calculations must be verified to ensure that the circuit breaker meets safety and performance standards. However, in practice, various factors—such as manufacturing defects, poor contact design, improper installation, and inadequate maintenance—can cause the resistance to exceed acceptable limits. Additionally, rapid temperature rise during operation is a major contributor to increased resistance. Repeated testing and inconsistent resistance values across different phases also contribute to the problem. Normally, the resistance should be around 97μΩ, but when it exceeds this value, it can disrupt normal operations and pose a risk to the entire system.
1.2 High Operating Temperatures
(1) Prolonged operation under heavy loads can cause the circuit breaker to overheat, leading to loosening of internal components and increased resistance. This is especially common in breakers that experience frequent operations, as repeated cycles can degrade the integrity of the contacts and connections.
(2) Poor-quality manufacturing and design flaws can also result in higher resistance. Different manufacturers may use varying materials and techniques, which can affect the performance and consistency of the circuit breaker. These differences can lead to irregularities in resistance values, ultimately causing the main circuit resistance to exceed the standard.
2. Solutions for Addressing Excessive Main Circuit Resistance2.1 Data Testing and Analysis
According to data collected in China, many circuit breakers exhibit excessive main circuit resistance during operation. To address this, engineers and technicians must conduct thorough inspections and analyses of the circuit breaker's condition. By monitoring resistance values and analyzing the internal operating state, they can identify the root causes and develop targeted solutions. For example, Table 1 shows that the B-phase and C-phase of certain circuit breakers have resistance values exceeding the standard. Under normal conditions, the resistance should not exceed 151μΩ. If it does, immediate action is required to prevent operational failures and ensure the safety and efficiency of the power system.
2.2 Maintenance and Repair Procedures
During operation, staff should perform comprehensive checks on the circuit breaker’s condition to detect and address potential issues early. This includes inspecting the resistance loops, tightening loose connections, and replacing faulty components. It is also important to examine the dynamic and static contacts of the circuit breaker to ensure they are functioning properly. Advanced diagnostic tools such as SF6 gas analysis, micro-water detection, and leak testing can help assess the overall health of the circuit breaker. If all parameters meet the required standards, the circuit breaker can be safely returned to service. Regular maintenance and careful monitoring of internal performance are essential to maintaining stable resistance levels and ensuring long-term reliable operation.
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